Advanced catalysts for automotive applications

ABSTRACT

Embodiments of present inventions are directed to an advanced catalyst. The advanced catalyst includes a honeycomb structure with an at least one nano-particle on the honeycomb structure. The advanced catalyst used in diesel engines is a two-way catalyst. The advanced catalyst used in gas engines is a three-way catalyst. In both the two-way catalyst and the three-way catalyst, the at least one nano-particle includes nano-active material and nano-support. The nano-support is typically alumina. In the two-way catalyst, the nano-active material is platinum. In the three-way catalyst, the nano-active material is platinum, palladium, rhodium, or an alloy. The alloy is of platinum, palladium, and rhodium.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.12/962,490, filed Dec. 7, 2010 which claims priority to U.S. ProvisionalPatent Application Ser. No. 61/284,329, filed Dec. 15, 2009 and entitled“MATERIALS PROCESSING,” which are hereby incorporated herein byreference in their entirety as if set forth herein.

BACKGROUND OF THE INVENTION

A catalytic converter for a car uses a catalyst to convert, for example,three harmful compounds in car exhaust into less harmful compounds. Thethree harmful compounds include hydrocarbons in the form of unburnedgasoline, carbon monoxide formed by the combustion of gasoline, andnitrogen oxide created when heat in the engine forces nitrogen in theair to combine with oxygen. There are two main structures used incatalytic converters—honeycomb and ceramic beads. Most automobiles todayuse the honeycomb structure. The honeycomb structure is housed in amuffler-like package that comes before the exhaust pipe. The catalysthelps to convert carbon monoxide into carbon dioxide, the hydrocarbonsinto carbon dioxide and water, and the nitrogen oxides back intonitrogen and oxygen.

Various methods of manufacturing the catalyst used in the catalyticconverter exist in the art. FIG. 1A illustrates a first conventionalmethod of manufacturing the catalyst. The first method is known as aone-dip process. At a step 105, micron-sized platinum (Pt) ions areimpregnated into micron-sized alumina (Al₂O₃) ions, resulting inmicro-particles. The micro-particles have platinum atoms on the aluminaions. At a step 110, a wash coat is made using micron-sized oxides thatinclude pint size alumina and pint size silica (SiO₂), a certain amountof stabilizers for the alumina, and a certain amount of promoters. At astep 115, the micro-particles are mixed together with the wash coat. Ata step 120, a cylindrical-shaped ceramic monolith is obtained. Across-section of the monolith contains 300-600 channels per square inch.The channels are linear square channels that run from the front to theback of the monolith. At a step 125, the monolith is coated with thewash coat. This can be achieved by dipping the monolith in the washcoat. As such, the channels of the monolith are coated with a layer ofwash coat. At a step 130, the monolith is dried. The layer of wash coathas an irregular surface, which has a far greater surface area than aflat surface. In addition, the wash coat when dried is a porousstructure. The irregular surface and the porous structure are desirablebecause they give a high surface area, approximately 100-250 m²/g, andthus more places for the micro-particles to bond thereto. As themonolith dries, the micro-particles settle on the surface and pores ofthe monolith. At a step 135, the monolith is calcined. The calcinationbonds the components of the wash coat to the monolith by oxide to oxidecoupling. The catalyst is formed. FIG. 1B illustrates a microscopic view145 of a channel of the monolith 140 that is coated with the layer ofwash coat 150 having platinum atoms 155.

FIG. 2A illustrates a second conventional method of manufacturing thecatalyst. The second method is known as a two-dip process. At a step205, a wash coat is made using micron-sized oxides that include pintsize alumina and pint size silica, a certain amount of stabilizers forthe alumina, and a certain amount of promoters. At a step 210, acylindrical-shaped ceramic monolith is obtained. At a step 215, themonolith is coated with the wash coat such as via dipping. As such, thechannels are also coated with a layer of wash coat. Typically, the layerof wash coat has an irregular surface which has a far greater surfacearea than a flat surface. FIG. 2B illustrates a microscopic view 250 ofa channel of the monolith 245 coated with the layer of the wash coat255. Returning to FIG. 2A, at a step 220, the monolith is dried. Thewash coat when dried is a porous structure. At a step 225, the monolithis calcined. The calcination bonds the components of the wash coat tothe monolith by oxide to oxide coupling. Micron-sized alumina oxides arethen impregnated with micron-sized platinum ions and other promotersusing a method that is well known in the art. Specifically, at a step230, platinum is nitrated, forming salt (PtNO₃). The PtNO₃ is dissolvedin a solvent such as water, thereby creating a dispersion. At step 235,the monolith is dipped into the solution. At a step 240, the monolith isdried. At a step 245, the monolith is calcined. The catalyst is formed.FIG. 2C illustrates another microscopic view 250′ of the channel of themonolith 245′ coated with the layer of wash coat 255′ having platinumatoms 260.

FIG. 3A illustrates a microscopic view 305 of a surface of the layer ofthe wash coat after calcination. Platinum atoms 310 are attached tooxygen atoms of the alumina. When exhaust gas goes through the catalyticconverter, the platinum atoms 310 help reduce the harmful compounds byconverting them into less harmful compounds. However, these variousmethods of manufacturing the catalyst used in the catalytic convertersuffer from a number of shortcomings. For example, the platinum atoms310 are not fixed to their bonded oxygen atoms of the alumina and areable to move around to other available oxygen atoms as illustrated inFIGS. 3B-3C. As the platinum atoms 310 move, the platinum atoms 310begin to coalesce with other platinum atoms resulting in largerparticles 315, as shown in FIG. 3D, and a more energetically favorablestate. It is understood that as the platinum particles become larger, itdetrimentally affects the catalyst since surface area of the platinumatoms decreases. In high temperature applications, such as in an agedcatalytic converting testing, the movement of platinum atoms ismagnified. In addition, since cost of platinum is extremely expensive,excessive use of platinum is unwanted.

The present invention addresses at least these limitations in the priorart.

SUMMARY OF THE INVENTION

In one aspect, a catalytic converter includes a honeycomb structure withan at least one nano-particle on the honeycomb structure. In someembodiments, the at least one nano-particle includes nano-activematerial and nano-support. The nano-active material is typically on thenano-support. The nano-active material is platinum, palladium, rhodium,or an alloy. The alloy is of platinum, palladium, and rhodium. Thenano-support is alumina. In other embodiments, the nano-support includesa partially reduced alumina surface, which limits movement of thenano-active material on a surface of the nano-support.

In another aspect, a cordierite substrate in a catalytic converterincludes a first type of nano-particles, a second type ofnano-particles, and a third type of nano-particles. In some embodiments,the first type of nano-particles includes nano-active material andnano-support. The nano-active material is platinum and the nano-supportis alumina. The nano-support includes a partially reduced aluminasurface, which limits movement of the nano-active material on a surfaceof the nano-support. In other embodiments, the second type ofnano-particles comprises nano-active material and nano-support. Thenano-active material is palladium and the nano-support is alumina. Thenano-support includes a partially reduced alumina surface, which limitsmovement of the nano-active material on a surface of the nano-support.In other embodiments, the third type of nano-particles comprisesnano-active material and nano-support. The nano-active material isrhodium and the nano-support is alumina. The nano-support includes apartially reduced alumina surface, which limits movement of thenano-active material on a surface of the nano-support.

Yet, in another aspect, a method of making a catalytic converterincludes creating a dispersion using an at least one nano-particle andobtaining a wash coat. In some embodiments, the at least onenano-particle includes nano-active material and nano-support. Thenano-active material is platinum, palladium, rhodium, or an alloy. Thenano-support is alumina. The nano-support includes a partially reducedalumina surface, which limits movement of the nano-active material on asurface of the nano-support. In other embodiments, the creating stepcomprises mixing a carrier material and different catalyst materials ina high temperature condensation technology, thereby producing the atleast one nano-particle, and combining it with a liquid. The carriermaterial is alumina. The different catalyst materials include platinum,palladium, and rhodium. Typically, the high temperature condensationtechnology is plasma. Alternatively, the creating step comprises mixinga carrier material and a first catalyst material in a high temperaturecondensation technology, thereby producing a first type ofnano-particles, mixing the carrier material and a second catalystmaterial in the high temperature condensation technology, therebyproducing a second type of nano-particles, mixing the carrier materialand a third catalyst material in the high temperature condensationtechnology, thereby producing a third type of nano-particles, collectingtogether the first type of nano-particles, the second type ofnano-particles, and a third type of nano-particles, and combining with aliquid. The carrier material is alumina. The first catalyst material isplatinum. The second catalyst material is palladium. The third catalystmaterial is rhodium.

Yet, in other embodiments, the method of making a catalytic converterfurther includes mixing the dispersion with the wash coat, applying themix to a monolith, drying the monolith, and calcining the monolith.Alternatively, the method of making a catalytic converter furtherincludes applying the wash coat to a monolith, drying the monolith,calcining the monolith, administering the dispersion to the monolith,drying the monolith, and calcining the monolith.

Yet, in another aspect, a method of making a three-way catalyticconverter includes creating a dispersion by using different types ofnano-particles, obtaining a wash coat, mixing the dispersion with thewash coat, applying the mix to a monolith, drying the monolith, andcalcining the monolith. The creating step includes using a hightemperature condensation technology. In some embodiments, the hightemperature condensation technology is plasma. Each of the differenttypes of nano-particles comprises nano-active material and nano-support.The nano-active material is platinum, palladium, rhodium, or an alloy.The nano-support is alumina. The nano-support includes a partiallyreduced alumina surface, which limits movement of the nano-activematerial on a surface of the nano-support.

Yet, in another aspect, a method of making a three-way catalyticconverter includes creating a dispersion using different types ofnano-particles, obtaining a wash coat, applying the wash coat to amonolith, drying the monolith, calcining the monolith, administering thedispersion to the monolith, drying the monolith, and calcining themonolith. The creating step includes using a high temperaturecondensation technology. In some embodiments, the high temperaturecondensation technology is plasma. Each of the different types ofnano-particles includes nano-active material and nano-support. Thenano-active material is platinum, palladium, rhodium, or an alloy. Thenano-support is alumina. The nano-support includes a partially reducedalumina surface, which limits movement of the nano-active material on asurface of the nano-support.

Yet, in another aspect, a method of making a two-way catalytic converterincludes creating a dispersion by using same type of nano-particles,obtaining a wash coat, mixing the dispersion with the wash coat,applying the mix to a monolith, drying the monolith, and calcining themonolith. The creating step includes using a high temperaturecondensation technology. In some embodiments, the high temperaturecondensation technology is plasma. Each of the same type ofnano-particles includes nano-active material and nano-support. Thenano-active material is platinum. The nano-support is alumina. Thenano-support includes a partially reduced alumina surface, which limitsmovement of the nano-active material on a surface of the nano-support.

Yet, in another aspect, a method of making a two-way catalytic converterincludes creating a dispersion using same type of nano-particles,obtaining a wash coat, applying the wash coat to a monolith, drying themonolith, calcining the monolith, administering the dispersion to themonolith, drying the monolith, and calcining the monolith. The creatingstep includes using a high temperature condensation technology. In someembodiments, the high temperature condensation technology is plasma.Each of the same type of nano-particles includes nano-active materialand nano-support. The nano-active material is platinum. The nano-supportis alumina. The nano-support includes a partially reduced aluminasurface, which limits movement of the nano-active material on a surfaceof the nano-support.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B illustrate a first conventional method of manufacturing acatalyst.

FIGS. 2A-2C illustrate a second conventional method of manufacturing thecatalyst.

FIGS. 3A-3C illustrate activity on a surface of a layer of wash coat onthe monolith using the first conventional method and the secondconventional method.

FIG. 3D illustrates platinum atoms coalesced into a large particle.

FIG. 4 illustrates a first inventive process of creating an advancedcatalyst in accordance with the present invention.

FIG. 5 illustrates a first inventive process of creating an advancedcatalyst in accordance with the present invention.

FIG. 6A illustrates a first method of creating a dispersion inaccordance with the present invention.

FIG. 6B illustrates a nano-particle in accordance with the presentinvention.

FIG. 7A illustrates a second method of creating a dispersion inaccordance with the present invention.

FIG. 7B illustrates a collection of different nano-particles inaccordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to implementations of the presentinvention as illustrated in the accompanying drawings. The drawings maynot be to scale. The same reference indicators will be used throughoutthe drawings and the following detailed description to refer toidentical or like elements. In the interest of clarity, not all of theroutine features of the implementations described herein are shown anddescribed. It will, of course, be appreciated that in the development ofany such actual implementation, numerous implementation-specificdecisions must be made in order to achieve the developer's specificgoals, such as compliance with application, safety regulations andbusiness related constraints, and that these specific goals will varyfrom one implementation to another and from one developer to another.Moreover, it will be appreciated that such a development effort will bea routine undertaking of engineering for those of ordinary skill in theart having the benefit of this disclosure.

The following description of the invention is provided as an enablingteaching which includes the best currently known embodiment. One skilledin the relevant arts, including but not limited to chemistry, physicsand material sciences, will recognize that many changes can be made tothe embodiment described, while still obtaining the beneficial resultsof the present invention. It will also be apparent that some of thedesired benefits of the present invention can be obtained by selectingsome of the features of the present invention without utilizing otherfeatures. Accordingly, those who work in the art will recognize thatmany modifications and adaptations to the present inventions arepossible and may even be desirable in certain circumstances, and are apart of the present invention. Thus, the following description isprovided as illustrative of the principles of the present invention andnot in limitation thereof, since the scope of the present invention isdefined by the claims.

Harmful compounds from internal combustion engines include carbonmonoxide (CO), hydrocarbons (H_(a)C_(b)), and oxides of nitrogen(NO_(x)). Two forms of internal combustion engines are diesel enginesand gas engines. A catalytic converter is designed to reduce theseharmful compounds by converting them into less harmful compounds. Asdiscussed above, conventional catalysts used in catalytic converters usemicro-particles such as micron-sized oxides and micron-sized catalystmaterials (e.g. platinum). Embodiments of the present invention usenano-sized oxides and nano-sized catalyst materials to create advancedcatalysts usable in catalytic converters of diesel engines and gasengines.

The term “nano-particle” is generally understood by those of ordinaryskill to encompass a particle having a diameter in the order ofnanometers, as described herein.

Diesel Engines

A diesel engine includes a diesel oxidation catalyst (DOC), a separateNOx reduction technology, and a diesel particulate filter (DPF). The DOCis a two-way catalytic converter, which converts (1) CO and O₂ to CO₂and (2) H_(a)C_(b) and O₂ to CO₂ and H₂O. The DOC uses platinum as anoxidizing agent. Conventional methods of creating the DOC usemicron-size platinum ions. Embodiments of the present invention usenano-sized platinum particles instead. FIGS. 4-5 illustrate twoinventive processes of creating an advanced DOC catalyst in accordancewith the present invention. The separate NOx reduction technologyreduces the NO_(x) emissions by using urea as a reducing agent. The DPFcatches subparticles (e.g. nongaseous hydrocarbons) from an exhaust gasof the diesel engine.

FIG. 4 illustrates a first inventive process 400 for creating theadvanced DOC catalyst in accordance with the present invention. At astep 405, nano-active materials are pinned or affixed to nano-supports,forming nano-particles, by using a high temperature condensationtechnology such as a plasma gun. In some embodiments, the nano-activematerials are gaseous platinum atoms, and the nano-supports are someform of alumina, such as aluminum plus oxygen. For the sake of brevity,platinum will be discussed herein, but it will be apparent to those ofordinary skill in the art that different platinum group metals can beused to take advantage of their different properties. Since nano-activematerials are strongly attached to nano-supports, movement orcoalescing/conglomeration of the nano-active materials is limited,prevented, or both. The nano-particles are then combined with a liquidto form a dispersion. The nano-particles and the dispersion are createdusing methods described in detail in U.S. patent application Ser. No.12/001,643, filed Dec. 11, 2007, which is hereby incorporated byreference. At a step 410, a wash coat is obtained. The wash coat iscommercially purchased or is made. Typically, the wash coat is a slurry.The wash coat is made by using micron-sized oxides that include aluminaand silica. In some embodiments, a certain amount of stabilizers for thealumina and a certain amount of promoters are also added to the washcoat. Typically, there is no difference between the commerciallypurchased wash coat and the created wash coat. At a step 415, thedispersion is mixed with the wash coat. At a step 420, acylindrical-shaped ceramic monolith is obtained. The monolith contains alarge proportion of cordierite since cordierite has a high resistance tothermal shock. In some embodiments, the monolith is a honeycombstructure. A cross-section of the monolith preferably contains 300-600channels per square inch. The channels are preferably linear squarechannels that run from the front to the back of the monolith. At a step425, the monolith is coated with a layer of the wash coat. This can beachieved by dipping the monolith in the wash coat. The channels of themonolith are also coated with a layer of wash coat. Since the wash coatcontains the nano-particles, nano-platinum particles are also on thesurface of the monolith. At a step 430, the monolith is dried. At a step435, the monolith is calcined. The calcination bonds the components ofthe wash coat to the monolith by oxide to oxide coupling. In addition,the calcination allows the nano-active materials to strongly attach tothe nano-supports because the nano-supports have a partially reducedalumina surface. As such, the advanced DOC catalyst is formed.

FIG. 5 illustrates a second inventive process 500 for creating theadvanced DOC catalyst in accordance with the present invention. At astep 505, nano-active materials are pinned or affixed to nano-supports,forming nano-materials, by using a high temperature condensationtechnology such as a plasma gun. In some embodiments, the nano-activematerials are gaseous platinum atoms and the nano-supports are some formof alumina, such as aluminum plus oxygen. Since nano-active materialsare strongly attached to nano-supports, movement orcoalescing/conglomeration of the nano-active materials is limited,prevented, or both. The nano-particles are then combined with a liquidto form a dispersion. At a step 510, a wash coat is obtained. The washcoat is commercially purchased or is made. The wash coat is made byusing micron-sized oxides that include alumina and silica. In someembodiments, a certain amount of stabilizers for the alumina and acertain amount of promoters are also added to the wash coat. Typically,there is no difference between the commercially purchased wash coat andthe created wash coat. At a step 515, a cylindrical-shaped ceramicmonolith is obtained. At a step 520, the monolith is coated with a layerof the wash coat such as via dipping. As such, the channels of themonolith are also coated with a layer of the wash coat. At a step 525,the monolith is dried. At a step 530, the monolith is calcined. At astep 535, the dispersion is applied to the monolith via dipping. At astep 540, the monolith is dried. At a step 545, the monolith iscalcined. The calcination bonds the components of the wash coat to themonolith by oxide to oxide coupling. As such, the advanced DOC catalystis formed

In order for the wash coat to get good bonding to the monolith, both pHlevel and viscosity of the wash coat must be in a certain range.Typically, the pH level must be between four and five to achieveoxide-oxide coupling. If the pH level is too low, then the viscosity istoo high; as such, the wash coat is a paste instead of a slurry. If thepH level is too high, then the viscosity is too low; as such, even aftercalcination, the wash coat does not bond to the monolith. Although theuse of nanomaterials applied to the advanced DOC catalyst is described,the use of nanomaterials is able to be applied to the DPF and the NOxreduction technology used in the diesel engine. Other catalysts in theautomation space are also contemplated.

Gas Engines

A gas engine cycles from oxygen rich to oxygen poor (e.g., an oxidizingstate to a reducing state). As such, a conventional catalytic converterfor gas engines includes an oxidation catalyst and a reduction catalyst.The reduction catalyst is a first stage in the conventional catalyticconverter. The reduction catalyst uses platinum and rhodium to helpreduce NOx emissions. For example, rhodium catalyzes CO and NO₂ to N₂and CO₂. The oxidation catalyst is a second stage in the conventionalcatalytic converter. It reduces unburned hydrocarbons and carbonmonoxide by oxidizing them using platinum and palladium. For example,platinum catalyzes CO and O₂ to CO₂ and catalyzes H_(a)C_(b) and O₂ toCO₂ and H₂O. Palladium catalyzes H_(a)C_(b) and O₂ to CO₂ and H₂O. Theoxidation catalyst aids reaction of the carbon monoxide and hydrocarbonswith the remaining oxygen in the exhaust pipe. Accordingly, the gasengine uses a three-way catalytic converter to reduce the three harmfulcompounds.

Conventional methods of creating the three-way catalytic converter usemicron-sized catalytic materials and supports, as discussed above. Inaddition, the conventional methods use multiple dippings to getpalladium ions, rhodium ions, and platinum ions on the monolith since adip that includes, for example, palladium ions and rhodium ions wouldproduce palladium-rhodium alloys, which is not beneficial in certainconditions and/or applications. Embodiments of the present invention usenano-sized catalytic materials and supports instead. In additions,embodiments of the present invention allows a dip to include palladiumions, rhodium ions, and platinum ions without creating palladium-rhodiumalloys, because the different ions have different solid phases.

Methods of creating the advanced three-way catalyst for gas engines aresimilar to the methods of creating the DOC as discussed above. Thedifference is in the initial steps 405 and 505 of FIGS. 4-5,respectively. Specifically, instead of using just gaseous platinum atomsin the dispersion, gaseous palladium atoms and gaseous rhodium atoms arealso used.

FIG. 6A illustrates a first method of creating the dispersion inaccordance with the present invention. Catalyst materials includeplatinum 615, palladium 620, and rhodium 625. Other catalyst materialsare contemplated. Carrier material includes alumina 630. The catalystmaterials 615, 620, 625 and carrier material 630 are mixed in a plasmagun. After vaporizing the catalyst materials and carrier material toform a vapor cloud and quenching the vapor cloud, the vapor cloudprecipitates nano-particles. FIG. 6B illustrates a nano-particle 600 inaccordance with the present invention. The nano-particle 600 comprises anano-active material 610 and a nano-support 605. Since the plasma gun isextremely chaotic, the catalyst materials form into an alloy. As such,the nano-active material 610 is an alloy. Since a ratio of thenano-active material 610 consisting of platinum, palladium, and rhodium,depends on an initial ratio of each of the catalyst materials used,different forms of alloys are formed on the nano-support 605. Thenano-particles 600 are combined with the liquid to form the dispersion.

FIG. 7A illustrates a second method of creating the dispersion inaccordance with the present invention. Instead of mixing platinum 615,palladium 620, rhodium 625, and alumina 630 in the plasma gun, each ofthe catalyst materials are separately mixed with alumina 630 in theplasma gun. As such, after vaporizing and quenching each of the catalystmaterials, three different nano-particles are formed. A collection ofthe different nano-particles are combined with the liquid to form thedispersion. The three different nano-particles are illustrated in FIG.7B. A first nano-particle 600′ is a platinum nano-active material 635 onthe alumina nano-support 605. A second nano-particle 600″ is a palladiumnano-active material 640 on the alumina nano-support 605. A thirdnano-particle 600′″ is a rhodium nano-active material 645 on the aluminanano-support 605. A size of the nano-active material is able to becontrolled based on a quantity of the nano-active material that wasinitially placed in the plasma gun. Concentration of each differentnano-particle 600′, 600″, 600′″ is able to be individually and/orcollectively controlled.

After creating a dispersion either using the first method (asillustrated in FIG. 6A) or the second method (as illustrated in FIG.7A), the first inventive process 400 continues at a step 410 and thesecond inventive process 500 continues at a step 510, as illustrated inFIGS. 4-5, respectively.

While the invention has been described with reference to numerousspecific details, one of ordinary skill in the art will recognize thatthe invention can be embodied in other specific forms without departingfrom the spirit of the invention. Thus, one of ordinary skill in the artwill understand that the invention is not to be limited by the foregoingillustrative details, but rather is to be defined by the appendedclaims.

We claim:
 1. A method of making a catalytic converter comprising:loading feed material into a plasma reactor, the feed materialcomprising active material and a support material; vaporizing the activematerial and the support material in the plasma reactor thereby forminga vapor cloud of active material and support material; condensing thevapor cloud of active material and support material, thereby formingsolidified nanoparticles comprising nano-active material andnano-support material; and applying a wash coat comprising thesolidified nanoparticles comprising nano-active material andnano-support material to a substrate to produce a catalytic converter.2. The method of claim 1, wherein the nano-active material comprisesplatinum.
 3. The method of claim 1, wherein the nano-active materialcomprises palladium.
 4. The method of claim 1, wherein the nano-activematerial comprises rhodium.
 5. The method of claim 1, wherein thenano-active material is an alloy.
 6. The method of claim 1, wherein thenano-support comprises alumina.
 7. The method of claim 1, wherein thenano-support comprises a partially reduced alumina surface, thepartially reduced alumina surface configured to limit movement of thenano-active material on a surface of the nano-support.
 8. The method ofclaim 1, wherein the feed material comprises a plurality of differentactive materials.
 9. The method of claim 8, wherein the support materialcomprises alumina.
 10. The method of claim 8, wherein the differentactive materials include platinum, palladium, and rhodium.
 11. Themethod of claim 1, wherein the wash coat comprises micron sized oxideparticles.
 12. The method of claim 1, wherein the wash coat comprisesmicron sized alumina particles.
 13. A method of making a catalyticconverter comprising loading a first feed material into a plasmareactor, the first feed material comprising first active material and afirst support material; vaporizing the first active material and thefirst support material in the plasma reactor thereby forming a vaporcloud of first active material and first support material; condensingthe vapor cloud of first active material and first support material,thereby forming solidified first nanoparticles comprising firstnano-active material and first nano-support material; loading a secondfeed material into a plasma reactor, the second feed material comprisingsecond active material and a second support material; vaporizing thesecond active material and the second support material in the plasmareactor thereby forming a vapor cloud of second active material andsecond support material; condensing the vapor cloud of second activematerial and second support material, thereby forming solidified secondnanoparticles comprising second nano-active material and secondnano-support material; and applying the first nanoparticles comprisingfirst nano-active material and first nano-support material and thesecond nanoparticles comprising second nano-active material and secondnano-support material to a substrate to produce a catalytic converter.14. The method of claim 13, further comprising: loading a third feedmaterial into a plasma reactor, the third feed material comprising thirdactive material and a third support material; vaporizing the thirdactive material and the third support material in the plasma reactorthereby forming a vapor cloud of third active material and third supportmaterial; condensing the vapor cloud of third active material and thirdsupport material, thereby forming solidified third nanoparticlescomprising third nano-active material and third nano-support material;and applying the third nanoparticles comprising third nano-activematerial and third nano-support material to the substrate.
 15. Themethod of claim 14, wherein at least one of the first support material,the second support material, and the third support material comprisesalumina.
 16. The method of claim 14, wherein the third active materialcomprises rhodium.
 17. The method of claim 14, wherein the first activematerial comprises platinum, the second active material comprisespalladium, and the third active material comprises rhodium.
 18. Themethod of claim 13, wherein the first active material comprisesplatinum.
 19. The method of claim 13, wherein the second active materialcomprises palladium.
 20. A method of making a three-way catalyticconverter comprising: loading a first feed material into a plasmareactor, the first feed material comprising an oxidation active materialand a first support material; vaporizing the first oxidation activematerial and the first support material in the plasma reactor therebyforming a vapor cloud of oxidation active material and first supportmaterial; condensing the vapor cloud of oxidation material and firstsupport material, thereby forming solidified oxidation nanoparticlescomprising oxidation nano-active material and first nano-supportmaterial; loading a second feed material into a plasma reactor, thesecond feed material comprising reduction active material and a secondsupport material; vaporizing the reduction active material and thesecond support material in the plasma reactor thereby forming a vaporcloud of reduction active material and second support material;condensing the vapor cloud of reduction active material and secondsupport material, thereby forming solidified reduction nanoparticlescomprising reduction nano-active material and second nano-supportmaterial; and applying the oxidation nanoparticles comprising oxidationnano-active material and first nano-support material, and the reductionnanoparticles comprising reduction nano-active material and secondnano-support material to a substrate.
 21. The method of claim 20,wherein the oxidation active material comprises platinum.
 22. The methodof claim 20, wherein the oxidation active material comprises palladium.23. The method of claim 20, wherein the reduction active materialcomprises rhodium.
 24. The method of claim 20, wherein the oxidationactive material is an alloy.
 25. The method of claim 20, wherein thefirst support comprises alumina.
 26. The method of claim 20, wherein thefirst support material comprises a partially reduced alumina surface,the partially reduced alumina surface configured to limit movement ofthe nano-active material on a surface of the nano-support.
 27. Themethod of claim 20, further comprising: loading a third feed materialinto a plasma reactor, the third feed material comprising secondoxidation active material and a third support material; vaporizing thesecond oxidation active material and the third support material in theplasma reactor thereby forming a vapor cloud of second oxidation activematerial and third support material; condensing the vapor cloud ofsecond oxidation active material and third support material, therebyforming solidified second oxidation nanoparticles comprising secondoxidation nano-active material and third nano-support material; andapplying the second oxidation nanoparticles comprising second oxidationnano-active material and third nano-support material to the substrate.28. The method of claim 27, wherein the oxidation active materialcomprises platinum, the second oxidation active material comprisespalladium, and the reductive active material comprises rhodium.
 29. Amethod of making a two-way catalytic converter comprising: loading afeed material into a plasma reactor, the first feed material comprisinga first oxidation active material and a first support material;vaporizing the first oxidation active material and the first supportmaterial in the plasma reactor thereby forming a vapor cloud of firstoxidation active material and first support material; condensing thevapor cloud of first oxidation material and first support material,thereby forming solidified oxidation nanoparticles comprising firstoxidation nano-active material and first nano-support material; andapplying the oxidation nanoparticles comprising first oxidationnano-active material and first nano-support material to a substrate. 30.The method of claim 29, wherein the first oxidation active materialcomprises platinum.
 31. The method of claim 29, wherein the firstnano-support material comprises alumina.
 32. The method of claim 29,wherein the first nano-support material comprises a partially reducedalumina surface, the partially reduced alumina surface configured tolimit movement of the first nano-active material on a surface of thefirst nano-support material.
 33. The method of claim 29, wherein thefirst oxidation active material comprises palladium.
 34. The method ofclaim 29, wherein the first oxidation active material is an alloy.